U.S. patent number 10,033,173 [Application Number 15/688,007] was granted by the patent office on 2018-07-24 for masonry box positioning support.
This patent grant is currently assigned to Hubbell Incorporated. The grantee listed for this patent is Hubbell Incorporated. Invention is credited to Steven J. Johnson, Krzysztof W. Korcz.
United States Patent |
10,033,173 |
Korcz , et al. |
July 24, 2018 |
Masonry box positioning support
Abstract
An electrical box support is provided for coupling to the side
wall of an electrical box to support the electrical box in an
opening formed in a hollow core building block. The support has a
flange at the front edge and tab at a front edge that clips onto
the side wall of the electrical box. A spring member extends from a
rear side edge and curls toward the front edge. The spring member
has an end that is directed toward the front edge and spaced from
the flange a distance to contact the inner surface of the block
while the flange contacts the outer surface of the block. The tab
at the front edge of the support has a hook for engaging an inner
edge of the electrical box to couple the support to the electrical
box and to prevent sliding of the support on the electrical
box.
Inventors: |
Korcz; Krzysztof W. (Grainger,
IN), Johnson; Steven J. (Buchanan, MI) |
Applicant: |
Name |
City |
State |
Country |
Type |
Hubbell Incorporated |
Shelton |
CT |
US |
|
|
Assignee: |
Hubbell Incorporated (Shelton,
CT)
|
Family
ID: |
54065587 |
Appl.
No.: |
15/688,007 |
Filed: |
August 28, 2017 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20170358912 A1 |
Dec 14, 2017 |
|
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
15441580 |
Feb 24, 2017 |
9748752 |
|
|
|
14204491 |
Mar 28, 2017 |
9608419 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16M
13/02 (20130101); H02G 3/121 (20130101); F16B
2/243 (20130101); H02G 3/12 (20130101); Y10T
29/49872 (20150115) |
Current International
Class: |
H02G
3/12 (20060101); F16B 2/24 (20060101); F16M
13/02 (20060101) |
Field of
Search: |
;174/480,481,482,483,490,503,50,53,57,58,54,61 ;220/3.2-3.9,4.02
;248/906,343 ;52/220.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Estrada; Angel R
Attorney, Agent or Firm: Michael Best & Friedrich,
LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of co-pending, prior-filed U.S.
patent application Ser. No. 15/441,580, filed Feb. 24, 2017, which
is a continuation of U.S. patent application Ser. No. 14/204,491,
filed Mar. 11, 2014, now U.S. Pat. No. 9,608,419. The entire
contents of these documents are hereby incorporated by reference.
Claims
What is claimed is:
1. A support for mounting an electrical box on a support structure,
the support comprising: a body configured to be coupled to the
electrical box; a flange coupled to the body and extending
substantially perpendicular to a plane of the body and configured
to be parallel to an outer edge of the electrical box, the flange
integrally formed with the body and configured to contact the
support structure; and a biasing member coupled to the body and
including a contact end extending toward the flange, the biasing
member biased toward the flange to capture a portion of the support
structure against the flange.
2. The support of claim 1, wherein the biasing member includes a
first guide member and a second guide member, the first guide
member extending along an inclined plane away from the contact end
in a first direction, the second guide member extending along an
inclined plane away from the contact end in a second direction.
3. The support of claim 2, wherein each of the first guide member
and the second guide member includes a first portion and a second
portion extending from the first portion, the second portion
forming an inclined plane relative to the first portion.
4. The support of claim 3, wherein each second portion is spring
biased with respect to the associated first portion.
5. The support of claim 1, further comprising at least one tab
extending from an edge of the body and configured to engage a side
wall of the electrical box adjacent an open end.
6. The support of claim 5, wherein each tab includes a side edge
and a hook projecting outwardly for engaging the electrical
box.
7. The support of claim 1, wherein the biasing member is a first
biasing member positioned proximate a first end of the body, and
further comprising a second biasing member positioned proximate a
second end of the body, the second biasing member including a
contact end extending toward the flange and biased toward the
flange to capture a portion of the support structure against the
flange.
8. The support of claim 1, wherein the flange is removably coupled
to the body by a frangible portion.
9. The support of claim 1, further comprising a spring-biased tab
extending from the body for contacting a side surface along an
opening in the support structure, the tab positioned between the
flange and the contact end of the first biasing member.
10. An electrical box assembly comprising: an electrical box having
a first side wall, a second side wall, and an opening positioned
between an edge of the first side wall and an edge of the second
side wall; and a support coupled to one of the first side wall and
the second side wall, the support including, a body, a flange
coupled to the body and extending substantially perpendicular to a
plane of the body and configured to engage a support structure, the
flange extending in a direction substantially parallel to the edges
of the first wall and the second wall, the flange integrally formed
with the body, and a biasing member coupled to the body and
including a contact end extending toward the flange, the biasing
member biased toward the flange to capture a portion of the support
structure against the flange.
11. The assembly of claim 10, wherein the support further includes
a tab having a having a first end engaging the edge of the one of
the first side wall and the second side wall.
12. The assembly of claim 11, wherein the tab includes a side edge
and a hook projecting outwardly with respect to the first end for
engaging the electrical box.
13. The assembly of claim 12, wherein the electrical box includes
an inwardly extending flange positioned adjacent the opening, the
hook engaging the flange to secure the support relative to the
electrical box.
14. The assembly of claim 10, wherein the biasing member includes a
first guide member and a second guide member, the first guide
member extending away from the contact end and defining a first
guide surface, the second guide member extending away from the
contact end and defining a second guide surface.
15. The assembly of claim 14, wherein each of the first guide
member and the second guide member includes a first portion and a
second portion extending from a distal end of the first portion,
the second portion forming an inclined plane relative to the first
portion.
16. The assembly of claim 15, wherein each second portion is spring
biased with respect to the associated first portion.
17. The assembly of claim 10, wherein the biasing member is a first
biasing member positioned proximate a first end of the body, and
the support further including a second biasing member positioned
proximate a second end of the body, the second biasing member
including a contact end extending toward the flange and biased
toward the flange to capture a portion of the support structure
against the flange.
18. The assembly of claim 10, wherein the flange is removably
coupled to the body by a frangible portion.
19. The assembly of claim 10, wherein the support further includes
a spring-biased tab extending from the body for contacting a side
surface of the support structure, the tab positioned between the
flange and the contact end of the first biasing member.
Description
FIELD
The present invention is directed to a support bracket for mounting
an electrical box. In particular, the invention is directed to an
electrical box support for supporting and positioning an electrical
box in an opening in a hollow core building block and to a method
for mounting the electrical box.
BACKGROUND
During construction of a wall it is desirable to mount an
electrical junction box in a manner so that the electrical junction
box does not move or shift during construction of the wall and
during use after completion of the structure. Numerous mounting
devices have been proposed for permanently and/or temporarily
mounting electrical boxes in the cavity of a wall during
construction.
The standard outlet boxes often require mechanical fasteners to
secure the electrical box permanently in place to a wall stud or
other support structure. The mechanical fasteners are usually
positioned to orient the electrical box in the desired location so
that the outer edge of the electrical box is flush with the outer
face of the wall.
The mounting of electrical boxes in concrete structures generally
requires a different mounting assembly for holding the electrical
box in position while the wall is being formed. In addition,
concrete wall and building block walls do not enable the usual
fasteners that are used in wood walls and studs since nail, screws
and other fasteners cannot be easily driven into the wall.
Electrical boxes are required to be secured to the wall to prevent
movement of the box after installation. Hollow concrete blocks
provide a particular difficulty in mounting electrical boxes since
there are no surfaces that can readily accommodate fasteners.
Various methods have been proposed for mounting or supporting
electrical boxes during construction of the concrete walls and
block walls. One manner of mounting the electrical box is to
provide a sheet metal form with various tabs that can hold the
electrical box in position while the cement or mortar sets. These
devices often require the device to be positioned between the
joints during the construction of the wall which can interfere with
the structural integrity of the joint. These devices also require
the use of cement or mortar to hold the support in place.
Various devices and methods have been proposed for mounting an
electrical box during construction. One example is disclosed in
U.S. Pat. No. 2,581,755 to Dieffenderfer which discloses an
electrical connection box having a bracket member for mounting to
the outer sides of the walls of the box. The brackets are folded to
form an outwardly projecting flange and overlap the front side of
the wall. Slots are provided for receiving mounting screws to
attach the bracket to the box. The bracket has inwardly projecting
bendable arms with weakened zones and straps integral with the arms
that are folded in a reverse direction. The electrical box and the
brackets are inserted into the opening in the wall and the straps
are folded outwardly causing the arms to bend and contact the inner
surface of the wall.
U.S. Pat. No. 2,736,450 to Atkinson discloses an outlet box
securing device. The securing device has a hook portion for
contacting the outer edge of the electrical box, a flat portion
extending from the hook portion and a spring arm forming a U-shaped
loop. The spring arm has one end that contacts the inside surface
of the opening to apply a spring force between the side edge of the
opening in the wall and the electrical box.
U.S. Pat. No. 3,184,191 to Esoldi discloses an electrical box
holder having legs formed in a U-shaped for engaging the open end
of the electrical box. The center leg of the holder is pulled
outwardly with respect to the electrical box causing the body of
the holder to bend 90 degrees and contact the inner surface of the
wall. The center leg is then folded over the edge of the electrical
box.
U.S. Pat. No. 3,337,168 to Albrecht discloses an electrical box
support having a pair of outwardly extending legs that are inserted
through the opening in the wall to contact the inner surface of the
wall. Tabs are then folded over the front edge of the electrical
box to secure the electrical box in place.
U.S. Pat. No. 3,362,667 to Ginsberg discloses an electrical switch
box support having an outer wall for contacting the outer surface
of the wall and an inner wall contacting the inner surface of the
wall and forming a channel therebetween. The body of the support
includes tabs that are bent over the open edge of the electrical
box to attach the electrical box to the support.
U.S. Pat. No. 4,183,486 to Esoldi discloses an electrical box
holder that is inserted into the opening in the wall between the
edges of the opening in the side wall of the electrical box. The
holder includes a bendable and collapsible center portion and leg
extensions on each side of the center portion. The leg extensions
extend beyond the front face of the electrical box and the wall and
are pulled outwardly causing the center portion to bend and engage
the inner surface of the wall.
U.S. Pat. No. 4,693,438 to Angell discloses an electrical box
retainer having a U-shaped clip like member having an outwardly
extending spring biased flange. The spring biased flange is
inserted between the outer edge of the electrical box and the
opening in the wall to contact the inner surface of the wall. The
main body of the clip is bent over the inner edge of the electrical
box.
U.S. Pat. No. 4,669,371 to Sarazen et al. discloses a mounting
spring for a foundation vent. The spring clips to the front edge of
the vent and has a pair of spring biased legs to contact the inner
edge of the opening in the wall.
U.S. Pat. No. 5,494,244 to Walton discloses a similar mounting clip
for an air diffuser. The mounting clip has a U-shaped portion that
slides onto the inner edge of the opening in the wall and an
inwardly extending leg to contact the outer surface of the
vent.
U.S. Pat. No. 5,661,264 to Reiker discloses an electrical box
having a U-shaped mounting bracket is attached to the rear wall of
the electrical box. The mounting bracket has outwardly extending
legs for supporting the electrical box.
U.S. Pat. No. 6,648,277 to De Leu discloses an electrical box
mounting strap for supporting an electrical box within a cavity of
the concrete block. The mounting strap has a configuration to
conform to the surface of the cavity of the block and has a leg
portion to support the rear and side walls of the electrical box to
prevent the electrical box from moving inwardly into the cavity of
the concrete block.
U.S. Pat. No. 7,455,266 to Faircloth discloses an electrical
conduit support for use in concrete block. The support has a main
body portion with a plurality of openings for receiving the
conduits and outwardly extending tabs or flanges that contact the
upper surface of the concrete block and is captured between the
adjacent concrete blocks.
U.S. Pat. No. 8,109,054 to Thomas et al. discloses a fastener for
an electrical box within a concrete block. The fastener has a front
portion, a center portion and an end portion. The end portion and
the center portion of the fastener are inserted through the utility
box with part of the end portion extending beyond the back surface
of the utility box. The front portion rests across the front
surface of the utility box. The end portion is secured against the
back surface of the utility box to maintain the position of the
utility box within the wall.
While the prior devices are generally suitable for their intended
purpose there is a continuing need in the industry for improved
methods and devices for mounting electrical boxes during
construction of concrete and block walls.
SUMMARY
The present invention is directed to a method and to a device for
mounting an electrical box in a wall or other support structure.
The invention is particularly directed to a bracket or support for
positioning an electrical box in the cavity of a hollow core
building block, such as a hollow concrete building block or masonry
wall.
Accordingly, an object of the invention is to provide a support
member for supporting an electrical box in an opening of a building
block during construction of a wall or other structure.
Another feature of the invention is to provide a support that can
be coupled directly to a standard electrical box and is able to
support the electrical box and position the electrical box in an
opening in a building block.
The electrical box support of the invention is particularly
suitable for mounting and positioning the electrical box in an
opening formed in a hollow core cement building block. The support
is able to attach directly to the electrical box and to attach the
electrical box to the block without interfering with the
construction of the wall and without the use of cement, mortar,
adhesives or fasteners to hold the support and the electrical box
in place. After completion of the wall or other structure, the
mortar used in the construction can be used to fix the electrical
box within the opening in the block.
The electrical box support in one embodiment of the invention has a
tab that can clip onto a wall of the electrical box to fix the
support to the electrical box. The tab can have a hook, projection
or barb that can engage a surface of the electrical box to attached
the support to the electrical box and prevent movement of the
support relative to the electrical box. In other embodiments, the
support is attached to the electrical box by welding.
The electrical box support is a one-piece unitary member formed
from sheet steel or other material that is cut and bent to the
finished form. The support can be made of other material, such as
plastic, that is sufficiently strong and resilient to support the
electrical box.
Accordingly, one feature of the invention is to provide a support
that is easily assembled with the electrical box and can easily
slide and fit into the opening formed in a building block for
supporting the electrical box. The support of the invention can be
attached to a standard electrical box as known in the art without
the need to modify the box.
Another feature of the invention is to provide a support for an
electrical box having an outwardly extending spring biased tab
configured for contacting the inner surfaces of the opening in a
building block for retaining and positioning the electrical box
within the opening during the construction of a wall or other
structure. In one embodiment of the invention, the support has an
outwardly extending flange for contacting the outer surface of the
building block and a spring member for contacting the inner surface
of the building block where the spring biased tab is positioned
between the flange and the spring member.
Another feature of the invention is to provide a support for an
electrical box to position the electrical box within an opening in
a building block where the support has a removable or separable
flange for contacting the outer surface of the building block to
position the electrical box during construction. After installation
of the electrical box and construction of the wall or other
structure, the flange can be separated from the support. In one
embodiment, the flange connected to the support by a frangible
portion forming a break line so that the flange can be separated
from the support by bending along the break line.
The various features and aspects of the invention are basically
attained by providing an electrical box support for mounting an
electrical box in an opening of a hollow core building block. The
support comprises a substantially planar body configured for mating
with a first side wall of the electrical box. The body has a first
longitudinal end, a second longitudinal end, a first side edge and
a second side edge. A tab extends from the first side edge of the
body and is configured for coupling the support to an open edge of
the first side wall of the electrical box to position the first
side edge of the body adjacent to the open outer edge of the
electrical box. A flange is coupled to the first side edge of the
body and extends substantially perpendicular to a plane of the body
opposite the tab and has a dimension to contact an outer surface of
the block and to orient the outer edge of the electrical box at the
outer surface of the block. A spring member having a first end
coupled to the second side edge of the body and a first leg portion
extending away from the body. A second contact end of the spring
member extends towards the flange. The second contact end is spring
biased toward the flange and is positioned to contact an inner
surface of the block to capture the block between the flange and
the second end of the spring member and support the electrical box
in a hollow cavity of the block.
The features of the invention are also attained by providing an
electrical assembly comprising an electrical box and support. The
electrical box has a first and a second side wall, a first and
second end wall and an open front. The electrical box support has a
body with a first longitudinal end, a second longitudinal end, a
first side edge and a second side edge. A first tab extends from
the first side edge of the body and is configured for coupling to
the first side wall of the electrical box. A flange is coupled to
the first side edge of the body and extends substantially
perpendicular to a plane of the body. The flange has a dimension to
engage an outer surface of a hollow core building block. A spring
member has a first end coupled to the second side edge of the body
and a second end that is spring biased towards the flange and has a
dimension to engage an inner surface of the building block.
The features of the invention are also attained by a method of
mounting an electrical box in an opening in a hollow core building
block. The method comprises the steps of providing at least one
electrical box support and an electrical box. The electrical box
support has a substantially planar body having a first longitudinal
end, a second longitudinal end, a first side edge and a second side
edge. A spring member has a first end coupled to the second side
edge of the body and extending away from the flange, and a second
contact end extending towards the flange where the second contact
end of the spring member is spring biased toward the flange. The
electrical box and support assembly is positioned in an opening in
the hollow core building block and the flanges are positioned
against an outer surface of the block. The spring is biased into
contact with an inner surface of the block to mount the electrical
box with an open front edge substantially flush with the outer
surface of the block.
These and other features of the invention will become apparent from
the following detailed description of the invention, which taken in
conjunction with the annexed drawings discloses various embodiments
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief description of the drawings, in which:
FIG. 1 is a perspective view of the support and electrical box
assembly during installation in a building block in one embodiment
of the invention;
FIG. 2 is a side view of the support and electrical box installed
in the building block;
FIG. 3 is a perspective view of the support and electrical box
assembly;
FIG. 4 is a perspective view of the support being coupled to the
electrical box;
FIG. 5 is an enlarged sectional view of the FIG. 4 showing the
coupling tab of the support;
FIG. 6 is a perspective view of the support in one embodiment of
the invention;
FIG. 7 is a front view of the support of FIG. 6;
FIG. 8 is left side view of the support;
FIG. 9 is a right side view of the support;
FIG. 10 is an end view of the support;
FIG. 11 is a top view of the electrical box and support in a second
embodiment;
FIG. 12 is a front view of the electrical box and support of FIG.
11;
FIG. 13 is a top view of the electrical box and support in another
embodiment of the invention;
FIG. 14 is a front view of the electrical box and support of FIG.
13;
FIG. 15 is a perspective view of the electrical box and support in
a second embodiment of the invention;
FIG. 16 is a perspective view showing the electrical box and
support of FIG. 15 positioned in an opening in a building
block;
FIG. 17 is a perspective view of the support of FIG. 15;
FIG. 18 is a front view of the support of FIG. 17;
FIG. 19 is a rear view of the support of FIG. 17;
FIG. 20 is a side view of the support of FIG. 17;
FIG. 21 is an end view of the support of FIG. 17;
FIG. 22 is a top view showing the support and electrical box
position in the building block; and
FIG. 23 is a front view showing the electrical box positioned in
the building block.
DETAILED DESCRIPTION OF THE INVENTION
The preset invention is directed to an electrical box support and
to a method of mounting an electrical box in an opening in a
structure such as a wall. The present invention is further directed
to a support for retaining an electrical box in an opening formed
in a hollow core masonry building block or an opening in a concrete
wall.
Referring to the drawings, the invention includes an electrical box
support 10 that can be attached to an electrical box 12 to form an
electrical box assembly. The electrical box 12 can be a standard
electrical box with standard dimensions and shapes. In the
embodiment of FIG. 1, the electrical box 12 is a single gang box
having a substantially rectangular configuration. In other
embodiments, the electrical box can be a multi gang box as shown in
the embodiments of FIGS. 11-14.
As shown in FIGS. 1-4, the electrical box 12 has a pair of side
walls 14, end walls 16, a back wall and an open front 18 defined by
the front edges of the side walls 14 and end walls 16. In the
embodiment shown, the electrical box 12 includes a mounting flange
20 extending inwardly from each end wall 16 with a dimension for
mounting the electrical device, such as a wall switch or
receptacle. In the embodiment shown, the mounting flange 20 extends
between the side walls 14 to form a lip projecting into the opening
18 in the electrical box. Each mounting flange 20 includes a screw
hole 22 for receiving a mounting screw to attach the electrical
device to the box. An electrical conduit 23 can be coupled to the
electrical box 12 to supply wires to the electrical box and wiring
device as known in the art.
For purposes of illustrating the features of the electrical box and
support, the electrical device is not shown. It is to be understood
that the electrical device can be any suitable electrical wiring
device as known in the art that is commonly mounted to an
electrical box.
Referring to FIGS. 5-10, the electrical box support 10 includes a
body 24 which is substantially planar and has a substantially
rectangular configuration for complementing the dimensions of the
electrical box 12. The body 24 has a first longitudinal end 26, an
opposite second longitudinal end 28, a first side edge 30 forming a
front edge and a second side edge 32 forming the rear edge. As
shown in FIG. 2, the body 24 has a dimension to complement the
dimensions of the side wall of the electrical box 12 to lay flat
against the side wall of the electrical box. In one preferred
embodiment of the invention as shown in the drawings, two supports
10 are used in mounting the electrical box 12 where a support 10 is
attached to each of the side walls 14. In preferred embodiments of
the invention, the support 10 is coupled to at least one side wall
14 of the electrical box. In other embodiments, the support 10 can
be coupled to one or more end walls or combinations of the end
walls and side walls of the electrical box.
The support 10 in a preferred embodiment is made from sheet steel
that is cut and folded to form the various tabs and flanges.
Preferably, the steel has sufficient strength and resilience to
secure the electrical box in the opening of the building block as
discussed hereinafter in greater detail. Alternatively, the support
can be made of other material such as a molded one-piece plastic
material.
The support is preferably a one piece unitary member. A first tab
34 shown in FIG. 6 is provided for attaching the body 24 of the
support 10 to a wall, such as the side wall 14 of the electrical
box 12 as shown in FIGS. 3 and 4. In one preferred embodiment, two
tabs 34 are provided at or near each end of the body 24 along the
front edge 30. As shown in FIG. 6, the tab 34 is formed by a leg 36
with a substantially U-shape having a first end 38 attached to the
edge 30 and a second end extending toward the second side edge 32.
The main portion 40 of the leg 36 is oriented substantially
parallel to the plane of the body 24 and is spaced from the body 24
a distance corresponding substantially to thickness of the side
wall 14 of the electrical box 12 for coupling the support to the
side wall 14 by a friction fit. The end portion 42 is bent away
from the plane of the leg and the body 24 to form a guide and
assist in sliding the support onto the side wall of the electrical
box.
The leg 36 has a projection or barb forming a hook 44 facing
outwardly from the respective longitudinal end of the body 24. The
hook 44 is formed by an inclined edge 46 and an undercut shoulder
48 extending substantially parallel to the front edge 30 of the
body 24. In the embodiment shown, the hooks 44 and the tabs 34 are
positioned next to or adjacent the respective longitudinal ends of
the body and are spaced apart a distance to engage and coupled to
the edge of the inwardly extending mounting flanges 20 of the
electrical box 12 as shown in FIG. 4. The undercut shoulder 48 of
the hook 44 in one embodiment engages an inner surface of the
mounting flanges 20. The tabs 34 are preferably spaced apart a
distance so that each tab 34 engages and is coupled to the mounting
flanges 20 at the opposite ends of the electrical box 12 to limit
sliding of the support 10 within the opening along the longitudinal
dimension of the side wall of the electrical box. As shown in FIG.
9, the hook can extend outwardly from an end of the body 24. In
alternative embodiments, the end walls of the electrical box can be
formed with an aperture or detent that is positioned to engage the
hooks 44 for coupling the supports 10 to the electrical box 12.
The support 10 in this embodiment of the invention is attached to
the electrical box by sliding the tabs 34 over the edge of the
electrical box so that the hooks snap onto or under the edges of
the mounting flanges 20. Preferably, the tabs 34 are spaced apart a
distance corresponding to the space between the mounting flanges 20
so that the edges of the tabs 34 contact the mounting flanges 20 to
reduce or prevent sliding of the support along the length of the
side wall of the electrical box 12. The hooks 44 also resist
separation of the supports 10 from the electrical box 12 during
installation and during use, such as when a force is applied to the
electrical device and the electrical box 12 that could otherwise
cause the electrical box to separate from the support. The hooks 44
couple to the electrical box to fix the position of the electrical
box in the wall opening and prevent the electrical box from falling
into the wall cavity during use.
In the embodiment shown in FIGS. 3-10, the body 24 of the support
10 includes a second tab forming a coupling tab 50 for attaching
the support to the side wall of the electrical box. A coupling tab
50 is provided next to each of the tabs 34 at the ends of the side
edge 30 of the body 24. In the embodiment shown, the coupling tabs
50 are spaced inwardly with respect to the tabs 34. The coupling
tabs 50 are formed by a leg having a substantially U-shape with a
first end 52 attached to the first side edge 26 and a second end
extending toward the second side edge 28. A main portion 54 of the
coupling tabs 50 is substantially parallel to the plane of the body
24 and spaced from the body 24 a distance corresponding to the
thickness of the wall of the electrical box 12 so that the coupling
tabs 50 grip the wall of the electrical box by a friction fit. An
end portion 56 of each coupling tab 50 is angled away from the body
24 to assist in sliding the coupling tabs 50 onto the wall 14 of
the electrical box 12 during installation. Preferably, the coupling
tabs 50 and the tabs 34 are oriented so that the front edge 30 of
the body is at or closely positioned to the front edge of the
electrical box.
A flange 60 extends outwardly from the front edge 30 of the body 24
to position the support 10 and the electrical box 12 relative the
wall of the support structure such as the building block 74 shown
in FIG. 1 and FIGS. 11-14. The flange 60 extends substantially
perpendicular to the plane of the body 24 in a direction opposite
to tabs 34 and coupling tabs 50. In the embodiment shown, the
flange 60 has longitudinal length less than the length of the body
24 and a width sufficient to contact the outer surface of the
building block and stabilize the electrical box. In the embodiment
shown, the flange 60 is formed by bending the sheet metal blank
during manufacture of the support 10. In an alternative embodiment,
the flange 60 can be formed as a tab extending parallel to the
plane of the body 24. During installation of the electrical box,
the support can be positioned in the opening in the block and then
the flanges 60 can be bent flat against the surface of the block to
the position shown.
The body 24 has a spring member 62 for contacting the inner edge of
the building block. In the embodiment shown, the spring member 62
is coupled to the rear side edge 32 of the body 24. Alternatively,
the spring member 62 can be coupled to the front edge of the body
24 and positioned to extend away from the rear edge 32. In a
preferred embodiment, two springs 62 are provided at each end of
the rear side edge 32. Each spring 62 has a substantially U-shape
and is formed by a first leg 64 having a first end 66 coupled to
the rear side edge 32 of the body 24, and a second leg 67 having a
second distal end 68. The legs 64 and 67 are connected by a
connecting portion 69 as shown in FIG. 10. As shown in FIG. 10, the
leg 64 is bent so that the distal end 68 forms a return and extends
toward the flange 60 and the front side edge 30. The distal end 68
is preferably spaced from the flange 60 a distance to enable the
flange 60 and the distal end 68 of the spring member 62 to
frictionally engage the inner and outer surfaces of the building
block. Preferably, the spring member 62 is formed from metal having
sufficient resilience to spring bias the distal end 68 toward the
flange 60 to position the electrical box with respect to the
building block and secure the electrical box in place during
construction and during use of the electrical box.
As shown in FIGS. 7-10, the end 68 of the leg 64 is formed with
outwardly extending tabs forming guide members 70 extending away
from the plane of the end 68 and the spring 62. The guide members
are angled with respect to the leg 64 of the springs 62 at an angle
sufficient to assist the ends 68 in sliding along the inner surface
of the block during installation of the support 10.
In use, the support 10 is attached to the electrical box 12 by
sliding the tabs 34 and the coupling tabs 50 of the support 10 onto
the side walls 14 of the electrical box 12 so that the flange 60 is
positioned at or near the front edge of the electrical box 12. The
hooks 44 are snapped onto or under the inner edges of the mounting
flanges 20 to secure the support to the electrical box and to
prevent sliding of the support relative to the electrical box. In
preferred embodiments, a support 10 is attached to each side of the
electrical box 12 although in other embodiments a single support
can be used depending of the location of the electrical box, the
dimensions of the opening in the building block and the shape of
the hollow cavity of the building block. Referring to FIG. 1, the
assembly of the support 10 and the electrical box 12 is positioned
into an opening 72 cut or formed into a building block 74 during
construction of a wall. The building block 74 has a cavity forming
a hollow core 76 with an outer wall 78 having an outer surface 80
and an inner surface 82.
In the embodiment shown, the opening 72 is cut along an edge to
form the opening 72 with an open side. The assembly of the support
10 and the electrical box 12 slides into the opening 72 in the
direction of arrow 84. During the installation, the flange 60
contacts the outer surface 80 of the block 74 and the distal end 68
of the spring 62 contacts the inner surface 82. The angled guides
70 enable the distal ends 68 of the spring 62 to slide along the
inner surface 82 during installation. The spring 60 biases the
distal end 68 to contact the inner surface 82 of the block 74 with
sufficient force to retain the support 10 and the electrical box 12
in place during construction of a wall and to retain the electrical
box in a fixed position during use of the electrical box and
prevent separation and movement of the electrical box with respect
to the block 74.
In the embodiment shown in FIGS. 1-10, the support 10 is attached
directly to the side walls of the electrical box 12. In another
embodiment shown in FIGS. 11 and 12, the support 10 is coupled an
electrical box 88 having an extension collar 86 in substantially
the same manner as in the embodiment of FIGS. 1-10. The collar 86
is attached to the electrical box 88 which has a dimension larger
than the opening in the block. A cover plate 90 extending from the
base of the collar 88 is attached to the open end of the electrical
box 88. The collar 86 in the embodiment shown has a dimension for
supporting an electrical wiring device and includes inwardly
extending flanges 92 at the end wall 94 for fixing the hooks 44 of
the support 10 to the open end of the collar 86 as shown in FIG. 12
in a manner similar to the previous embodiment.
In the embodiment of FIGS. 13 and 14, the electrical box 94 is
shown as a three gang box for supporting a plurality of electrical
devices. The construction of the electrical box 94 is substantially
the same as the electrical box 12. The support 10 is attached to
the electrical box 94 is the same manner as in the previous
embodiment by the tabs and hooks 44.
In another embodiment shown in FIGS. 15-22, an electrical box
support 90 is attached to the side walls 92 of an electrical box 94
as an assembly. The electrical box 94 and the support 90 are
configured for sliding into an opening 96 formed in a hollow core
building block 98 as in the previous embodiment.
The support 90 has a body 100 with a first longitudinal end 102, a
second longitudinal end 104, a first side edge 106 and a second
side edge 108. The body 100 has a substantially planar
configuration for mating with the side wall 92 of the electrical
box 94. In the embodiment shown, the body 100 is attached to the
side wall 92 by spot welds at welding points 110 shown in FIG. 17
so that the support 90 is permanently fixed to the electrical box.
In a preferred embodiment of the invention, the support 90 is
formed from metal as a one piece integral unit formed by cutting
and stamping the sheet metal blank enfolding various portions of
the blank to form the support.
The first longitudinal edge 106 of the body 100 includes a flange
112 that extends substantially perpendicular to the plane of the
body 100. The flange 112 is coupled to the body by a fold line 114
defining a frangible portion so that the flange 112 can be
separated from the body by folding the flange along the fold line
and breaking the fold line 114 when it is desirable to separate the
flange. The body 100 is provided with recessed cutouts 116 adjacent
the connecting point of the flange 112 to assist in breaking the
flange from the body. In the embodiment shown, the flange 112
includes a main portion 118 with legs 120 coupled to the body 100
can be easily separated from the body 101 desired. The flange 112
has a dimension to contact the outer surface of the block 98 as
shown FIG. 16 to support and position the electrical box within the
opening 96 and so that the open end of the electrical box is
substantially flush with the outer face of the block 98.
Referring to FIG. 17-21, a tab 122 extends from the body 100 at an
incline with respect to the plane of the body 100. In one
embodiment as shown, the tab is coupled to the second side edge 108
and is integrally formed with the body 100. The tab 122 is coupled
to the body 100 along a connecting fold line 124 at the
longitudinal ends of the tab 122. Tab 122 has an outer edge 126
spaced from the body 100 so that the tab 122 is positioned between
the flange 112 and the spring member 128. The tab 122 is spring
biased outwardly with respect to the body 100 and is oriented to
contact the side surface of the opening 96 in the block 98. In the
embodiment shown in FIGS. 15 and 16, the tabs 122 of the support 90
contact the opposite sides of the opening 96 to center the
electrical box 94 within the opening 96. Preferably, the tabs 122
are spring biased outwardly to contact the surfaces of the opening
to assist in retaining the electrical box within the opening during
construction and to center the electrical box within the
opening.
The spring member 128 is formed to contact the inner surface of the
hollow core block 98 as in the previous embodiment and as shown in
FIGS. 10, 22 and 23. The spring member 128 is coupled to the body
100 along the second side edge 108 as shown FIG. 17-20, the spring
member 128 has a first end 130 coupled to the second side edge 108
of the body 100 to contact end 132 spaced from the flange 112 the
distance to capture the side wall of the building block 98 between
the flange and the contact end of the spring member 128.
The spring member 128 is formed by a first leg 134 and a second leg
136. The first leg 134 has an inner end coupled to the body 100 by
a fold line 138 and an outer end 140. Preferably, the first leg 134
is spring biased with respect to the body 100. In the embodiment
shown, the first leg 134 has a substantially V-shaped configuration
extending from the body 100 so that the respective legs of the
V-shape are coupled to the body 100 by the fold lines 138. The
first leg 134 is angled at an incline with respect to the body 100
and extends outwardly from the body 100 and away from the flange
112 as shown in FIG. 21. The second leg 136 extends from the outer
end 140 of the first leg 134. In the embodiment shown, the second
leg 136 is oriented substantially perpendicular to the plane of the
first leg 134 and extends in the direction generally towards the
flange 112.
The second leg 136 includes contact arms 144 defining guide members
to contact the inner surface of the building block 98 and to assist
in guiding the electrical box and support into the opening 196 in
the block 98. The contact arms 144 are formed by a first section
146 extending at an incline with respect to the second leg 136
towards the flange 112. The first section 146 has a distal end 148
defining a contact end surface of the spring 128. A second section
150 of the contact arm 144 extends from the distal end 148 at an
incline with respect to the plane of the first section 146 and
extends away from the flange 112 to form the contact arm 144 with a
substantially V-shape. In the embodiment shown, the spring member
128 is provided with two contact arms 144 extending in opposite
directions from the second leg 136 to form the contact surfaces of
the spring member 128 with the inner surface of the block 98. The
contact arms 144 are preferably spring biased with respect to the
second leg 36 along the fold line 152 between the side edges of the
second leg 136 and the end of the first section 146 of the contact
arms 144. The contact arms 144 are spring biased toward the flange
112 to engage the inner face of the block as shown in FIG. 22.
The support 90 in the embodiment shown is attached to the
electrical box by welding or other suitable fastening means so that
the flange 112 is positioned at the open end 154 of the electrical
box 94 as shown in FIG. 22. The electrical box and the support 90
are positioned in the opening 96 of the block 98 by sliding the
electrical box and support into the opening in the direction of
arrow 156 shown in FIG. 15. The contact arms 144 of the support 90
contact the inner surface of the block 98 while the flange 112
contacts the outer surface of the block as shown in FIG. 22. The
spring biased tabs 122 projects outwardly from the body 100 to
contact the inner edges of the opening 96 to position the
electrical box 94 within the opening 96. As shown in FIG. 22, the
tabs 122 preferably position the electrical box in substantially
the center of the opening 96. The contact arms 144 are biased
towards the flange 112 to capture the wall of the block 98 between
the contact arms 144 and the flange 112. The support 90 positions
the electrical box within the opening of the block during
construction of a wall or other structure. Cement or mortar used in
the construction of the wall can be used to fix the position of the
electrical box and support within the opening 96. Once the mortar
is set, the flanges 112 can be removed by bending along the fold
line 114. The flanges 112 can be removed to avoid interference with
the electrical components mounted within the electrical box and
faceplates or other devices mounted to the opening of the
electrical box.
While various embodiments have been shown, it will be understood
that various changes and modifications can be made without
departing from the spirit and scope of the invention as defined in
the appended claims.
* * * * *